Disposable absorbent article

ABSTRACT

A three dimensional disposable panty for holding a sanitary pad. The panty may have elasticized leg and waist openings and be stretchable about the hip and stomach regions of a user. The panty provides backup leakage protection to the sanitary pad. The panty includes an absorbent barrier composite positioned in the crotch area and extending into the body of the disposable panty front and back and over the leg elastics to trap pad leakage inside the pant and prevent liquid strike through onto outer clothing and bed linen.

FIELD OF THE INVENTION

[0001] This present invention relates to undergarments in general, andmore specifically to women's disposable undergarments having a fluidrepellent region and an absorbent layer to be used with a woman's normalfeminine care protection during her menstrual period.

BACKGROUND OF THE INVENTION

[0002] Regular undergarments in current use are made of cotton and/orsynthetic materials. The cotton and synthetic panties typically do notoffer barrier protection. Often the synthetic panties have a cottonlined crotch to absorb vaginal discharges or perspiration. Theabsorbent/barrier properties of regular undergarments are minimal suchthat any vaginal, discharge and/or heavy perspiration may strike throughonto outer clothing (i.e., penetration of liquid from the interior tothe exterior of the panty.)

[0003] Panty liners and feminine care sanitary napkins or pads used withregular undergarments have polyethylene backings that provide somebarrier properties needed to prevent liquid strike through. However, ifthe vaginal discharge extends to the sides or the ends of the pads itcan leak onto the undergarment. This leakage can stain the undergarment.Depending upon the amount of leakage, liquid may strike through or goaround the undergarment to stain outer clothing and or bedding. Womenwith heavy periods often use one or more maxi pads, double pads and/ortampons alone, or in combination, and change these pads and tamponsfrequently to prevent embarrassing, messy, leakage and/or staining ofouter clothing. In some cases, during their heaviest flow days, womenwill restrict their activities and stay home.

[0004] A majority of women experience some leakage of menses from theirpads to their undergarments. This varies from being limited to a smallnumber of pads leaking onto only the undergarment during light flow toleakage onto the wearer's outer clothing on almost half the pads wornduring heavy flow. Normally this leakage occurs at the side of theproduct, although end leakage is also a problem. Placement of maxi padsand overnight pads in the crotch of regular undergarments shows that, atbest, the pads lay on the leg elastic and, at worst, overhang the legelastics. This causes side leakage onto the undergarment and possiblyonto outer clothing. Typical leakage from the pads is caused by poor fitof the pad to the body, improper positioning of the pad by the user andlack of absorbency. Leakage from the undergarment onto the outerclothing is due to incompatibility between the pad width and the pantycrotch width and lack of barrier properties, in the panty materialaround the edge portion of the pad.

SUMMARY OF THE INVENTION

[0005] Briefly, this invention describes a three dimensional,disposable, discrete panty with fully elasticized leg and waist openingsthat is circumferentially stretchable about the hip and stomach regionsand which provides back-up leakage protection to feminine care products.It is particularly useful during the wearer's menstrual period, normallyoccurring in non-pregnant women about every four weeks, from menarche tomenopause.

[0006] The protection benefit is obtained by providing a flexiblesecondary absorbent associated with the crotch of the undergarment whichholds the primary absorbent in proper location for vaginal discharge(menses). The secondary absorbent extends from the crotch into the bodyof the undergarment front and back and may extend over the leg elastics.This provides an undergarment which is capable of trapping and absorbingthe leakage from the pad and preventing liquid strike through onto outerclothing and bed linen.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The present invention will be more fully understood and furtheradvantages will become apparent when reference is made to the followingdetailed description of the invention and the drawings, in which:

[0008]FIG. 1 is a top plan view of a panty article of the presentinvention in a preassembled flat configuration;

[0009]FIG. 2 is a perspective view of a full-sized, disposable menstrualpanty of the present invention.

[0010]FIG. 3 is a sectioned view taken along view lines 3-3 of FIG. 1and illustrating the outer cover, liner and elastics.

[0011]FIG. 4 is a sectioned view taken along view lines 4-4 of FIG. 1and illustrating the absorbent layer, barrier and outer cover.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] The following detailed description is made in the context of anarticle including a disposable panty for holding a sanitary pad in placeduring use. It is readily apparent, however, that the present inventioncan be employed with other disposable articles, such as femininetampons, incontinent garments and the like.

[0013] The disposable panty of FIG. 1 illustrates the preferredembodiment of the present invention in a flat configuration prior toassembly. In FIG. 1, a panty 12 is shown having an outer cover 13 whichincludes a front body portion 14, a back body portion 15, a front waistportion 16, a back waist portion 17, a crotch portion 18, waist liner 26(not shown), leg liner 38 (not shown) and body liner 80 (not shown).

[0014] The outer cover 13 is compliant and soft feeling to the wearer.The outer cover 13 may be liquid pervious, permitting liquids to readilypenetrate into its thickness, or impervious, resistent to thepenetration of liquids into its thickness. A suitable outer cover 13 maybe manufactured from a wide range of materials, such as natural fibers(e.g., wood or cotton fibers), synthetic fibers (e.g., polyester orpolypropylene fibers) or from a combination of natural and syntheticfibers or reticulated foams and apertured plastic films.

[0015] There are a number of manufacturing techniques which may be usedto manufacture the outer cover 13. For example, the outer cover 13 maybe woven, nonwoven, such as spunbonded, carded, or the like. A suitableouter cover 13 is carded, and thermally bonded by means well known tothose skilled in the fabric art. Alternatively, the outer cover is aspunbond. Ideally, the outer cover is a spunbond polypropylene nonwovenwith a wireweave bond pattern having a grab tensile of 19 pounds asmeasured by ASTM D1682 and D1776, a Taber 40 cycle abrasion rating of3.0 as measured by ASTM D1175 and Handle-O-Meter MD value of 6.6 gramsand CD value of 4.4 grams using TAPPI method T402. Suitably, thespunbond material is available from Kimberly-Clark Corporation, locatedin Roswell, Ga. The outer cover 13 has a weight from about 0.3 oz. persquare yard (osy) to about 2.0 osy and alternatively about 0.7 osy.Preferably, the outer cover of the undergarment has a printed pattern,is colored or is decoratively embossed.

[0016] Referring to FIGS. 1, 2 and 3, an edge 60 of front body portion14 is assembled with an edge 62 of the back body portion 15 to form aseal 64. Similarly, an edge 66 of the front body portion 14 is assembledwith an edge 68 of the back body portion 15 to form a seal 70. The waistportions 16 and 17, when assembled form a waist opening 20 for puttingon and taking off the panty 12. The waist opening 20 is surrounded atleast in part by a waist elastic 22. The waist elastic 22 is stretchedand attached to the waist portion 16. The waist elastic 22 is releasedafter attachment to produce waist folds or pleats 24 to allow expansionof the waist opening 20 so that the panty 12 can fit various sizedwomen. Because users of this invention generally prefer a brief stylepanty, the waist portion 16 of the panty 12 preferably comes to thenavel and is even around the wearer's waist. Having the panty 12 at thisheight and then drawing in the waist portion 16 with the waist elastic22 provides a snug fit. Alternative panty styles include bikini (e.g.regular leg cut and french leg cut) and hipster (e.g. regular leg cut orfrench leg cut).

[0017] Referring again to FIGS. 1 and 2, the front body portion 14 andthe back body portion 15 together with the crotch portion 18 forms legopenings 28 and 30, respectively, which are generally circular or ovalin shape. The leg openings 28 and 30 are each surrounded at least inpart by leg elastics 32 and 34, respectively. The leg elastics 32 and 34are stretched and attached to the front and back body portions 14 and 15and the crotch portion 18. The elastics are released after attachment toproduce leg folds or pleats 36 to allow expansion of the leg openings 28and 30 to fit various sized legs.

[0018] The front body portion 14 is usually divided into a front upperportion 40 and a front lower portion 42. Similarly, the back bodyportion 15 is divided into a back upper portion 41 and a back lowerportion 43. The upper portions 40 and 41 are preferably designed toinclude body elastics 44 which are capable of stretching to allow thewearer to put on the panty 12 and then readily resume the body elastic'snormal contracted form. This ensures a close or snug fit to differentbody and size forms. A number of body elastics 44 are positioned on boththe front and the back portions 40 and 41, respectively, at positionsbetween the waist opening 20 and the leg openings 28 and 30, so that thepanty 12 fits the wearer better, particularly around the body. The lowerbody portions 42 and 43 do not necessarily require elastics. If theouter cover incorporates the body elastic, the basis weight of the outercover and body elastic laminate may be as high as 5 osy.

[0019] In reference to the crotch portion 18 of FIG. 1, the functionaltotal capacity of normal pads worn during the menstrual cycle rangesfrom about 12 grams to about 63 grams. More typically, the capacity ofthe pads is above 20 grams. The marketing names associated with suchpads include “thin maxi”, “maxi”, “thick maxi” and “super maxi”. Thesewill be referred to as maxi pads. The entire absorbent core normallycontained in a maxi pad and which is used during medium to highmenstrual flow periods in the panty 12 is the “primary” absorbent 45.The absorbent which is associated with the crotch portion of the currentinvention is the “secondary” absorbent.

[0020] The crotch portion 18 of the panty 12 consists of an absorbentbarrier composite 46. The absorbent barrier composite 46 furtherconsists of a liquid barrier 48 and a secondary absorbent 50.Preferably, the thickness of the crotch portion 18 is less than about 4mm. The thickness is measured on a 4 inch (102 mm) square sample (legelastics removed) with a Mitutoyo Digamatic Indicator using a 3 inch (76mm) diameter acrylic platen and assembly to produce a pressure of 0.05psi. The liquid barrier 48 is needed to prevent liquid strike throughonto the outer clothing when leakage occurs on. the panty 12. The liquidbarrier 48 is located on the inside of the crotch portion 18 andconsists of a liquid impervious film such as polyethylene. Use of onlythe film would be hot and uncomfortable, would not be durable enough towithstand changing of pads and would smear any menses which leaked offof the primary absorbent 45. Any film crotch material in the prior artthat is elastic is nominally undesirable for the attachment of a padsince the stretch could detach the pad. Therefore, it is desirable toassociate the secondary absorbent 50 with a liquid barrier 48 which isnonelastic.

[0021] The secondary absorbent 50 should have a liquid capacity greatenough to absorb leakage of menses from the primary absorbent 45. Thesecondary absorbent 50 should preferably have a capacity (describedbelow) and a thickness substantially less than that of the primaryabsorbent 45, thus providing a nonbulky and flexible fit. The capacityof the secondary absorbent 50 should have a total capacity of aboutone-half of the primary absorbent 45. Preferably, the secondaryabsorbent 50 should have a total capacity of at least about 3 grams andnot more than 6 grams. More preferably, the total capacity of thesecondary absorbent 50 should be from about 4 grams to about 6 grams.However, the basis weight of or the type of secondary absorbent 50should be adjusted to provide resistance to flexibility of less thanaround 400 grams.

[0022] The absorbent barrier composite of the present invention has alow stiffness. The low stiffness allows the absorbent and barrier toremain attached to the conformable outer cover which conforms to a widerange of body sizes and shapes. Preferably the absorbent barriercomposite has a stiffness of less than 400 grams along any axis tested,more preferably less than 300 grams along any axis and less than 100grams along the axis parallel to the waist opening in the invention.

[0023] The secondary absorbent alone will have a stiffness of less than250 grams and preferably less than 100 grams along any axis and morepreferably less than 75 grams along the axis parallel to the waistopening in the invention.

[0024] The stiffness of the absorbent barrier composite is measured bypeak bending stiffness. Peak bending stiffness is measured by INDAStandard Test method IST 90.3-92-Standard Test Method for Handle-O-MeterStiffness of Nonwoven Fabrics. The nonwoven to be tested is deformedthrough a restricted slot opening by a blade, and the required force ismeasured. This force is a measure of both flexibility and surfacefriction of the absorbent.

Apparatus

[0025] The test apparatus is an Electronic Digital Read-OutHandle-O-Meter, Model #211-5 equipped with flat plates. The apparatus isavailable from Thwing-Albert Instrument Company in Philadelphia, Pa.;

Number and Preparation of Samples

[0026] For each procedure for this test, five samples should be preparedaccording to the method described in IST 90.3-92. For tests involvingthe absorbent barrier composite, the specimen should include allstructural components of the absorbent barrier composite including anymaterials or methods used to bond that composite together. For tests ofthe secondary absorbent only, the specimens should be all structuralcomponents of the secondary absorbent including materials or methods forbonding that secondary absorbent together.

Procedure

[0027] The procedure should be conducted as described in IST 90.3-92.The procedure makes provisions for altering specimen dimensions ifresultant grams readout exceeds the 100 gram capacity of the instrument.Reduction in sample size to result in a read-out within the range of theinstrument may be necessary for materials falling in the range of theabove description. Conduct all such modifications as described in IST90.3-92 and use the test unit conversion described in section 7.1 of IST90.3-92. The gap should be set at 0.25 inches (6 mm) as described insection 10.1 of the IST 90.3-92. The absorbent barrier composite shouldbe tested along an axis parallel to the direction in which the absorbentcomposite was manufactured (so-called machine direction) as well as theaxis perpendicular to the direction of the absorbent composite'smanufacture (so-called cross direction). In addition each side should betested along each axis. These steps are detailed in sections 10.1through 10.10 inclusive in IST 90.3-92.

Calculations

[0028] The maximum reading for each specimen is recorded per IST 90.3-92section 10.3. The five values are averaged for each axis and sidecondition tested. The results are reported as maximum grams reading foreach specimen. This differs from the millinewtons called for in IST90.3-92 sections 11 and 12. The average of all five values for eachcondition is calculated.

[0029] The total capacity of the primary absorbent 45 and the secondaryabsorbent 50 are determined as follows. Any panty adhesive release paperis removed from the pad to be tested. The total capacity of the primaryabsorbent 45 is determined using the entire napkin minus any releasepaper. The total capacity of the secondary absorbent 50 is determinedusing the absorbent barrier composite 46 of the panty 12 and the outercover 13. The specimen is weighed to the nearest 0.1 gram and acclimatedat standard relative humidity and temperature for two hours. Thespecimen is then submerged in a beaker of sterile saline (0.9% sodiumchloride solution obtainable from the Baxter Travenol Company ofDeerfield, Ill.), such that the specimen is totally submerged and is notbent or otherwise twisted or folded. The specimen is submerged for 10minutes. The specimen is removed from the saline and suspended for twominutes in a vertical position to allow the saline to drain out of thespecimen. The specimen is then placed body facing surface down onto anabsorbent blotter, such as filter paper #631 available from theFiltration Science Corp, Eaton-Dikmena Division of Mount Holly Springs,Pa. A uniform 17.6 grams per square centimeter load is placed over thespecimen to squeeze excess liquid out of the specimen. The absorbentblotter is replaced every 30 seconds until the amount of liquidtransferred to the absorbent blotter is less than 0.5 grams in a 30second period. The specimen is then weighed to the nearest 0.1 gram andthe dry weight of the specimen is subtracted from the final wet weight.The difference in grams is the total capacity of the specimen.

[0030] In construction of the absorbent barrier composite 46, the liquidbarrier 48 should retard the movement of the liquid through theabsorbent barrier composite 46 by making the barrier liquid resistant topenetration normally encountered under wearing conditions. The compositemay be rendered liquid impermeable by any method well known in the artsuch as coating the secondary absorbent 50 or by securing a separateliquid impermeable material to the secondary absorbent 50. Alternativelythe liquid barrier 48 consists of a liquid impervious film or foam whichis pervious to water vapor under normal wearing conditions. Morepreferred, the liquid barrier 48 has a water vapor transmission rate ofat least about 3500 grams/m²/day measured by ASTM E96-92. One example ofa suitable film is a 39.4 grams per square meter microporous filmproduced by Mitsui and sold by Consolidated Thermoplastics (CT) underthe tradename of ESPOIR® N-TAF-CT.

[0031] The secondary absorbent 50 may be any construction which isgenerally compressible, conformable, non-irritating to the wearer'sskin, capable of absorbing and retaining menstrual fluid. Optionally,the secondary absorbent 50 has first and second opposed faces andincludes an absorbent rich layer 51 and a support layer 53. Theabsorbent rich layer 51 may be manufactured in a wide variety of sizesand shapes (e.g., rectangular, hour-glass, etc. ) and from a widevariety of liquid absorbent materials, such as fiberized wood pulp.Examples of other suitable absorbent materials include creped cellulosewadding, absorbent foams, absorbent sponges, superabsorbent polymers, orany equivalent material or combination materials. The support layer 53may be any construction which is generally resistent to deterioration byliquids while being conformable, non-noisy and capable of holding theabsorbent rich layer 51 in place.

[0032] Alternatively, the absorbent rich layer 51 can range from 30 to80 gsm 1:1 blend of northern hardwood pulp and southern softwood pulp.The support layer 53 can be a 12-15 gsm spunbond. The pulp layer ishydroentangled through the spunbond. Alternatively, the combined layersmay then be microcreped. The liquid barrier 48 and the secondaryabsorbent 50 are bonded together using an adhesive 72 add-on of 3 to 7gsm. Optionally, the absorbent rich layer 51 is bonded to the barrier ofthe absorbent barrier composite 46. This arrangement permits improvedattachment, removal and reattachment of the primary absorbent 45 to thepanty 12. The liquid barrier 48 is bonded to the outer cover 13 on theinside of the panty with an adhesive 74 add-on of 5 to 10 gsm. Theliquid barrier 48 may be an adhesive film which bonds the secondaryabsorbent 50 to the outer cover 13. A suitable adhesive for bothapplications includes, for example, National Starch NS 34-5561 hot meltadhesive which is available from National Starch and Chemical Companylocated in Bridgewater, N.J.

[0033] The width of the crotch portion 18 between the leg elastics 32and 34 should be wide enough to lay the primary absorbent 45 between theedges without having the primary absorbent 45 obstruct the leg elastics.This allows the leg elastics 32 and 34 to contract and draw up the sidesof the crotch to accommodate the depth of the primary absorbent 45 beingused and give surface area within the crotch portion 18 to containleakage from the primary absorbent 45.

[0034] The minimum width of the crotch portion 18 should not be so wideas to seem bulky or uncomfortable, but a suitable width is at leastabout 2.75 inches (70 mm) between the leg elastics. The minimum width isadvantageous from about 3 inches (76 mm) to about 3.5 inches (89 mm).Optionally, the width is about 3 inches (76 mm). Preferably, the legelastics 32 and 34 are from about 0.375 inch (10 mm) to about 0.625 inch(16 mm) wide. More preferably, the width is about 0.5 inch (13 mm).Preferably, ruffle material on the edge of the leg openings 28 and 30outside the leg elastics 32 and 34 is less than about 0.25 inch (6 mm).More preferably, the ruffle material is less than about 0.125 inch (3mm). It is most desirable to eliminate the ruffle material from the edgeof the leg openings 28 and 30. The overall width of the crotch portion18 includes the width between the leg elastics 32 and 34, the width ofthe leg elastics 32 and 34 and the ruffle material outside the legelastics 32 and 34 to the edge of the leg openings 28 and 30.Preferably, the overall width of the crotch portion 18 should be atleast about 4 inches. (102 mm). The width of the absorbent barriercomposite 46 is sized in relation to the width of the crotch portion 18.Preferably, the width of the composite 46 is at least the width of thecrotch portion 18 between the leg elastics 32 and 34. More preferably,the width is equivalent to the width of the crotch portion 18.

[0035] The overall length of the absorbent barrier composite 46 shouldbe adequate to extend beyond the ends of the primary absorbent 45 tohelp prevent liquid strike through at these points when sleeping orsitting. This overall length is at least about 15 inches (382 mm) thusextending beyond the crotch portion 18 along the longitudinal centerlineA-A of the panty 12. Alternatively, the length should be in the range ofabout 15 inches (382 mm) to about 19 inches (484 mm). Optionally, thelength of the composite 46 is about 17 inches (433 mm).

[0036] The width of the absorbent barrier composite 46 beyond the crotchportion 18 should be at least as wide as the width of the crotch portion18. The width of the absorbent barrier composite 46 could be narrowedbeyond the crotch portion 18 but may compromise the leakage containment.More preferably, the width is from about 5 inches (127 mm) to about 12inches (306 mm), alternatively from about 5.5 inches (140 mm) to about7.5 inches (191 mm). Optionally, the width is about 6.5 inches (165 mm).

[0037] The present invention contemplates various shapes of thecomposite 46. One preferred composite has a non-rectangular shape withrounded ends which provides extensive coverage in the seat of thefinished panty 12. Another preferred absorbent barrier composite 46embodiment is rectangular in shape with rounded ends. The essentiallyrectangular-shaped absorbent barrier composite 46 is more preferredsince it can be squared off at the ends to provide a smoother appearancein the back of the panty 12. Line 76 may be embossed or printed on theinner surface of the crotch portion 18 to aid in placement of theprimary absorbent 45 by the wearer.

[0038] Referring to FIG. 3, the waist elastic 22 is shown covered with awaist liner 26. Referring to FIGS. 3 and 4, the leg elastics 32 and 34are shown covered by the absorbent barrier composite 46 and a leg liner38. Referring to FIG. 3, the body elastic 44 is shown covered with abody liner 80. The liner consists of a nonwoven or other soft materialfor contacting the wearer's skin.

[0039] The position and the shape of the leg openings 28 and 30 areimportant to avoid tightness in the crotch and groin area of the wearer,to obtain adequate buttocks coverage, and to prevent the panty 12 fromtilting forward, i.e. tilting such that the front waist edge dips lowerin relationship to the back waist edge. FIG. 1 illustrates the mostpreferred design for leg fit and buttocks coverage. The shape of thecurve across the top of the leg may be considered. If the curve is toodeep, the panty 12 will shift downward and backward resulting in a shortfront waist, increased back length and bagginess in the seat of thepanty. This causes the panty 12 to appear tilted when worn as evidenceby an unevenness around the waist of the wearer.

[0040] The leg openings 28 and 30 are important to the correctfunctioning of the panty 12. With the panty 12 laid out flat as in FIG.1, the majority of the back half of the leg opening preferably forms astraight line. More preferably the back edge of the leg opening isstraight for a length, θ, of at least about 70% of the length of theentire back half. The straight section θ of the back half of the legopening should form an acute angle with the longitudinal centerline,A-A, of the panty 12. More preferably, the line, θ, forms an angle, α,with the centerline A-A of the panty 12 of between about 50° and 65° andmost preferably about 60°. The majority of the edge of front half of theleg opening including lengths β and

also preferably forms a straight line. More preferably, the lengths ofedge β and

of the leg opening is straight for at least about 70% of the length ofthe front half. The straight section β of the front half of the legopening should form an angle with the centerline of the panty 12 ofbetween about 75° and 110° and most preferably about 90°.

[0041] Likewise, the shape of the arc at the inner groin area isimportant. If the arc is too shallow, tightness may be experienced atthe inner groin area. The preferred narrow crotch width reduces coverageof the buttocks. To compensate for such reduction, the back curve ispreferably adjusted downward. The arc between the crotch edge of the legopening and the back edge of the leg opening should start slightly infront of centerline B-B of the panty 12, see FIG. 1. This allows the legelastic to be positioned below the lower edge of the buttocks and helpsprevent the panty 12 from riding up when walking. This means that thestraight portion

of the inner edge of the leg opening is entirely forward of the panty 12centerline B-B.

[0042] The waist, leg and body elastics 22, 32, 34 and 44, respectively,are attached to the panty 12 on the outer cover 13 in generally astretched state by means known in the art, such as ultrasonic bonded,heat/pressure bonded or adhesively bonded. Materials suitable forelastics include a wide variety including but not limited to elasticstrands, yarn rubber, flat rubber, elastic tape, film-type rubber,polyurethane and elastomeric, tape-like elastomeric or foam polyurethaneor formed elastic scrim. Each elastic may be unitary, multipart orcomposite in construction.

[0043] The waist elastic 22 is about 0.5 inch (13 mm) wide. The elasticmay comprise threads, ribbons, a film or composite. The threads orribbons may be multiple and may be applied as a composite. Preferably,the waist elastic is threads, more preferably four threads are used asthe elastic and the threads are spaced about 0.17 inch (4.3 mm) apart.The threads may be made of any suitable elastomeric material. Onesuitable material is spandex such as Lycra® threads available fromDupont located in Wilmington, Del. Suitable waist elastics includethreads having a total decitex (g/10000 m) of about 3760 for 0.5 inch(13 mm) wide elastic. Adhesive 74 is used to bond the elastic to theouter cover 13 and the waist liner 26. A suitable adhesive includes, forexample, Findley H2096 hot melt adhesive which is available from FindleyAdhesives located in Milwaukee, Wis.

[0044] The leg elastics 32 and 34 are about 0.5 inch (13 mm) wide. Theelastic may comprise threads, ribbons, a film or composite. The threadsor ribbons may be multiple and may be applied as a composite. The frontand crotch leg elastics may be threads, preferably numbering threethreads which are spaced about 0.17 inch (4.3 mm) apart. Back elasticsnumbering up to six threads should have a width of about 0.75 inch (19mm) and a spacing of about 0.15 inch (3.8 mm) apart. The threads may bemade of any suitable elastomeric material. One suitable material isspandex such as Lycra® threads available from Dupont located inWilmington, Del. Suitable leg elastics include threads having a totaldecitex (g/10000 m) of about 3760 for a 0.5 inch (13 mm) wide elastic.Adhesive 74 is used to bond the elastic to the outer cover 13 and to theleg liner 38.

[0045] To provide a snug leg fit and to draw up the sides of the crotchportion 18 to form the primary absorbent cradle, the leg elastics 32 and34 are applied to the outer cover 13 under an elongation of about 250%.Preferably, during the application of the elastics, the elastics 32 and34 are segmented into multiple segments, each segment being elongated toa different degree and applied to the outer cover 13. In the case of twosegments, the front segment is elongated less than the back segment. Inthe case of three segments, the front and crotch segments are elongatedless than the back section. Preferably, the front and crotch segmentsare elongated to about 150% and the back segment is elongated to about250%. The segmenting and differing tensions allow easier pad attachment,less tightness in the groin area, and less bunching of the crotchportion 18 caused by high leg elastic retraction. The back leg elasticis under higher elongation to help keep the seat of the panty fromcreeping up with movement during use.

[0046] The body elastics 44 circumferentially surrounding the bodyportions 14 and of the panty 12 act independently to conform to thecontours of various body types and builds. This provides a smooth, snug,and comfortable fit within a given hip size range. Using higherelongation, closer spacing, and higher cross-sectional area in the waistelastic 22 than in the body elastics 44, the panty 12 takes on a roundedshape and provides good waist fit across the waist to hip ratiosencountered.

[0047] Preferably, in the front body portion the body elastics 44 adjoinboth the waist elastic 22 and leg elastics 32 and 34. In a panty 12, thebody elastics 44 are about 6.5 inches (166 mm) wide in the front andabout 6.0 inches (153 mm) wide in the back. The body elastics 44 arepreferably spaced about 0.25 inch (6 mm) apart.

[0048] The absorbent barrier composite 46 which extends up the frontand/or back body portions toward the waist portion is conformed to thewearer's body by the body elastic 44. The transition from the front andback lower portions to the front and back upper portions is thussmoothed.

[0049] The waist elastic 22 is desirably under a greater tension perunit width than the body elastics 44 in the upper body portion 40 toprovide the snug waist fit over the range of waist to hip ratios of thevarious body shapes. In the preferred embodiment, the tension on thewaist elastic 22 is coordinated with the tension of the body elastics 44to form a snug fit about the waist opening while providing a smoothtransition from the upper body portion 40 to the waist portion 16.

[0050] In the front and back body portions 14 and 15, the leg, waistand/or body liners may be expanded to cover the interior of the bodyportions 14 and 15. The leg, waist and/or body liners may exclude thecenter crotch portion 18 which is covered by the application of theabsorbent barrier composite 46. In the body portions where the absorbentbarrier composite 46 overlaps the liner, the composite is applied on topof any liner present so as to contact the wearer.

[0051] An acceptable range for the waist elastic tension is from about380 grams to about 1000 grams. More preferably, the tension at the waistis from about 575 grams to about 750 grams. The preferred leg elastictension is from about 375 grams to about 1000 grams. More preferably,the tension at the leg is from about 500 grams to about 700 grams. Thepreferred hip elastic tension is from about 500 grams to about 850grams. More preferably, the tension at the hip is from about 650 gramsto about 750 grams. The waist and leg tensions are determined asfollows. The appropriate gauge rod distance is selected from Tables 1and 2 for a given panty size and desired location measurement. This roddistance is the distance between the top of the upper peg and the bottomof the lower peg on the Chatillon DFG-2 Tensile Tester. TABLE 1 GaugeRod Distance Pant Size Waist Leg 5/6 354 mm 278 mm 7/8 392 mm 306 mm 9/10 468 mm 345 mm

[0052] TABLE 2 Gauge Rod Distance Pant Size Waist Leg 5/6/7 371 mm 288mm 8/9/10 445 mm 328 mm

[0053] Measurements are recorded on the tester in kilograms, theHOLD/NORM switch is set at “NORM”, the T/C switch is set at “T”(tension). The samples are conditioned and the testing is conducted in astandard laboratory atmosphere of a temperature of 23±2° C. and arelative humidity of 50±5% RH.

[0054] For determination of the waist tension, the edge along the bondedseam of the panty 12 is placed over the upper peg of the tester. Thepanty 12 is allowed to hang freely from the upper peg and the weight ofthe specimen is tared out.

[0055] The lower block is lifted upwards and the opposing waist edgealong the bonded seam is placed over the peg of the lower block. Theblock is lowered until the magnet of the tensile tester locks intoplace. The tester is activated and timed for two minutes. At twominutes, the tension displayed on the gauge is recorded. The tension inkilograms is converted to grams and the panty 12 is removed.

[0056] For determination of leg tension, the edge along the bonded seamnear the crotch fold is placed over the upper peg. The panty 12 isallowed to hang freely from the upper peg and the weight of the specimenis tared out.

[0057] The lower block is lifted upwards and the bonded seam along theopposing leg opening edge is placed over the peg of the lower block.

[0058] The block is lowered until the magnet of the tensile tester locksinto place. The tester is activated and timed for two minutes. At twominutes, the tension displayed on the gauge is recorded. The tension inkilograms is converted to grams and the panty 12 is removed. Thismeasurement represents the right leg tension. The test is repeated forthe left leg tension.

[0059] For determination of hip tension, the top and bottom side seamsof the body portion of the panty 12 are placed in the upper and lower 8inch wide jaws of an Instron Model 1122 equipped with a Sintech softwaresystem and the Interactive Materials Analysis Program (IMAP).

[0060] The tension program stretches the elastic body portion at a rateof 500 mm/minute until 1000 grams is reached. The crosshead then returnsto the starting position and repeats a second cycle. The stress-straingraph can be plotted and tension data points printed at 50, 60, 70, 80,90% of the full stretch (defined as length at 1000 grams) for first andsecond load and unload cycles. The tensions were taken from the secondcycle unload values at about 85% of full stretch.

[0061] The side seams 64 and 70 may be made on the inside or outside ofthe panty 12 or formed flat against the panty 12 to give a more finishedlook to the panty 12 and to prevent the seams 64 and 70 from showingthrough clothing. Optionally, the lateral edges 60, 62, 66 and 68 of thefront and back body portions are not overlapped but are formed flat andextend out laterally. The side seams 64 and 70 should be minimal inwidth while providing sufficient strength to be pulled up and down manytimes over a 24 hour wear period.

[0062] The side seams 64 and 70, respectively, of the outer cover 13 aresealed by means known in the art, such as ultrasonic bonding, stitching,heat/pressure bonding or adhesive bonding. The maximum seam strengthattainable is dependent upon materials used, bond pattern, pond width,and process settings of dwell time, power, and pressure. Suitable sideseams typically utilize ultrasonic bonding to achieve a seam strength ofat least 5 kg.

[0063] The seams 64 and 70 may have an unbonded portion outboard of thebonded area to provide for a soft edge to the seam. This unbondedportion can ranged from 2 to 3 mm in width. Alternatively, the entireseam width (bonded portion plus unbonded portion) may be less than about0.25 inch (6 mm). If the seam is trimmed or cut close to the outer edgeof the bond area, a sharp edge is produced along the seam edge which cancatch on clothes or be irritating to the wearer's skin.

[0064] The panty 12 was compared to panties constructed of cotton andpanties having a barrier but no secondary absorbent 50. Seventeen womenwere retained for this comparison. Each woman wore a selected maxi padwith each panty type until the pad leaked onto that panty type.Loose-fitting cotton shorts were worn by each woman over the panty whichcould be worn under their normal loose-fitting clothing. At the end ofeach test, the pad, panty and cotton shorts were collected. The pad,panty and shorts were photographed. The results of the comparison foundthat cotton panties had leakage to outer garments in 35.3% of the women,panties with barriers but no secondary absorbent 50 had leakage in 41.2%of the women and the panty 12 of this invention had leakage in only23.5% of the women.

[0065] Having thus described the invention in full detail, it will bereadily apparent that various changes and modifications may be madewithout departing from the spirit of the invention. All such changes andmodification are contemplated as being within the scope of the presentinvention, as defined by the following claims.

We claim:
 1. A disposable panty adapted to receive a primary absorbent,said primary absorbent having a liquid permeable inner sheet, a liquidimpermeable outer sheet and an absorbent member disposed therebetween,said disposable panty comprising: a) an outer cover having front andback body portions connected by a crotch portion, said front and backbody portions connected together to form a waist opening and two legopenings; and b) an absorbent barrier composite associated with saidcrotch portion, to which said primary absorbent is fastened and which,in use, holds said primary absorbent against the body of a user, saidabsorbent barrier composite having an impervious layer and an secondaryabsorbent.
 2. The disposable panty of claim 1 wherein said absorbentbarrier composite is essentially coterminous with the edge of the crotchportion.
 3. The disposable panty of claim 1 wherein said secondaryabsorbent is associated with the liquid impermeable outer sheet of saidprimary absorbent.
 4. The disposable panty of claim 1 wherein saidsecondary absorbent comprises a support layer and an absorbent richlayer.
 5. The disposable panty of claim 3 wherein said absorbent richlayer comprises pulp.
 6. The disposable panty of claim 1 wherein saidabsorbent barrier composite covers a portion of said front and back bodyportions.
 7. The disposable panty of claim 1 wherein said secondaryabsorbent has a total absorbent capacity of less than about one half ofthe capacity of said primary absorbent.
 8. The disposable panty of claim6 wherein said secondary absorbent has a total absorbent capacity ofless than about 6 grams.
 9. The disposable panty of claim 7 wherein saidsecondary absorbent has a total absorbent capacity of from about 3 gramsto about 6 grams.
 10. The disposable panty of claim 3 wherein saidprimary absorbent may be refastenably attached to said absorbent barriercomposite.
 11. The disposable panty of claim 1 wherein said primaryabsorbent has a total absorbent capacity of at least about 10 grams. 12.The disposable panty of claim 10 wherein said primary absorbent has atotal absorbent capacity of at least about 20 grams.
 13. The disposablepanty of claim 1 wherein said edge of said leg opening toward said backportion of said disposable panty is essentially linear and forms a 60°angle with the longitudinal centerline of said panty.
 14. The disposablepanty of claim 12 wherein said leg opening facing said front portion ofsaid disposable panty is essentially perpendicular to the longitudinalcenterline of said disposable panty.
 15. The disposable panty of claim13 wherein said outer cover carries at least one elastic around each ofsaid leg openings which forms a gather around each of said leg openings.16. The disposable panty of claim 14 wherein said outer cover carries atleast one elastic around said waist opening which forms a gather aroundthe waist.
 17. The disposable panty of claim 16 wherein said outer covercarries at least one elastic around said front and back body portionsand forms a gather around the body of said disposable panty.
 18. Thedisposable panty of claim 17 wherein said body elastic about saiddisposable panty extends from said waist opening to said leg openings.19. The disposable panty of claim 18 wherein said waist elastic has astress which is greater than the stress per unit width in said bodyelastic.
 20. The disposable panty of claim 19 wherein said leg elasticcomprises multiple individual elastic threads, and said waist elasticcomprises multiple individual elastic threads, said leg and waistelastic threads being spaced from about 4 mm to about 17 mm apart. 21.The disposable panty of claim 1 wherein said crotch region is wider thansaid primary absorbent.
 22. The disposable panty of claim 21 whereinwidth of said crotch portion is sized to be about 13 mm wider than thewidth of said primary absorbent selected for use by the user.
 23. Thedisposable panty of claim 22 wherein said crotch portion is at leastabout 102 mm in width.
 24. A disposable panty adapted to receive aprimary absorbent, said primary absorbent having a liquid permeableinner sheet, a liquid impermeable outer sheet and an absorbent memberdisposed therebetween, said panty comprising: a) an outer cover havingfront and back body portions connected by a crotch portion, said frontand back body portions connected together to form a waist opening andtwo leg openings; and b) an absorbent barrier composite associated withsaid crotch portion, to which said primary absorbent is fastened andwhich, in use, holds said primary absorbent against the body of a user,said barrier composite having an impervious layer and a secondaryabsorbent, c) said outer cover includes a leg elastic positioned aroundeach of said leg openings to form a gather around each said leg opening,a waist elastic positioned around said waist opening to form a gatheraround said waist opening and a body elastic positioned around saidfront and back body portions to form a gather of said front and backbody portions.
 25. The disposable panty of claim 24 wherein said waistelastic tension is from about 380 g to about 1000 g.
 26. The disposablepanty of claim 24 wherein said leg elastic tension is from about 375 gto about 1000 g.
 27. The disposable panty of claim 24 wherein said bodyelastic tension is from about 500 g to about 850 g.
 28. A disposablepanty adapted to receive a primary absorbent, said primary absorbenthaving a liquid permeable inner sheet, a liquid impermeable outer sheetand an absorbent member disposed therebetween, said disposable pantycomprising: a) an outer cover having front and back body portionsconnected by a crotch portion, said front and back body portionsconnected together to form a waist opening and two leg openings; b) anabsorbent barrier composite associated with said crotch portion, towhich said primary absorbent is fastened and which, in use, holds saidprimary absorbent against the body of a user, said barrier compositehaving impervious layer and an secondary absorbent; c) a majority of thelength of the back half of the edge of said leg opening is linear, saidlinear portion forming an angle with the longitudinal centerline A-A ofsaid panty of from about 50° to about 65°; and d) a majority of thelength of front half of the edge of said leg opening is linear, saidlinear portion forming an angle with the longitudinal centerline A-A ofsaid panty of from about 75° to about 110°.
 29. The disposable panty ofclaim 28 wherein said edge of said leg opening toward said back bodyportion of said disposable panty essentially forms a 60° angle with thelongitudinal centerline A-A of said panty.
 30. The disposable panty ofclaim 29 wherein said leg opening facing the front body portion of saiddisposable panty is essentially perpendicular to the longitudinalcenterline A-A of said disposable panty.
 31. The disposable panty ofclaim 1 wherein said absorbent barrier composite has a stiffness of lessthan about 400 grams.
 32. The disposable panty of claim 1 wherein saidsecondary absorbent has a stiffness of less than about 250 grams.